Dantherm BasX User manual

BasX
Service manual
EN
No. 039073 • rev. 1.0 • 08.03.2007

Der tages forbehold for trykfejl og ændringer
Dantherm can accept no responsibility for possible errors and changes
Irrtümer und Änderungen vorbehalten
Dantherm n’assume aucune responsabilité pour erreurs et modifications éventuelles

3
039073 • Version 1.0 • 05.03.2007
Introduction
Overview
Introduction This is the service manual for the Dantherm Air Handling BasX unit.
The index below shows the main sections of the manual. For further information see the
complete table of contents on page 4.
Warning It is the operator’s responsibility to read and understand this manual as well as
other information and to use the correct operation and maintenance procedure.
The unit should only be operated by qualified (trained) persons. Repair of cooling
circuit/electrical system must be done by skilled service engineers. If such precautions
are neglected, persons or equipment may be injured or damaged.
Not included This manual does not include information about:
•Transport, mounting, installation, start and commissioning of the unit
Separate instructions are delivered with the unit
•Function and use of the control
Separate instructions are delivered with the unit, if the control is included in the
delivery from Dantherm Air Handling A/S
•Technical information/data including electrical documentation
Delivered separately with the unit
Contents This service manual deals with the following:
Item See page
Introduction This page
Table of contents 4
General information 5
Service guide 6
Technical information 27
Index 33

4
Table of contents
Introduction This is the complete table of contents covering all sections in this service manual.
Each main section will begin with an introduction including a separate table of contents
covering the specific section.
Table of contents This service manual covers the following topics:
Topic See page
Introduction 3
Table of contents 4
General information 5
Service guide 6
Scheduling service inspections, overview 7
Preventive maintenance 9
How to service the cabinet 10
How to service fans and fan motors 11
How to service the cross-flow heat exchanger 13
How to service the rotary heat exchanger 15
How to service run-around heat exchangers 17
How to service the filter 19
How to service the heating coil 20
How to service the cooling coil 21
How to service dampers 22
Spare parts 24
Fault finding guide 25
Service agreement 26
Technical information 27
Dimensions 28
Driver for rotor exchanger 29
Flow calculation for plug fans 32
Index 33

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039073 • Version 1.0 • 05.03.2007
General information
Introduction This section includes general information on the unit and the service manual.
Target group The service manual’s target group is the service engineers that maintain the unit.
Not included in
the manual
The following is not included in this manual, but described separately:
•The transport, mounting and installation guide
•The user’s guide for control, if such is delivered
•Technical information, including electrical documentation
Copyright Copying of this service manual, or part of it, is forbidden without prior written permission
from Dantherm Air Handling.
Reservations Dantherm Air Handling reserves the right to make changes and improvements to the
product and the service manual at any time without prior notice or obligation.
EC-Declaration of
Conformity
Dantherm Air Handling A/S declares that the BasX units comply with the following
directives:
2006/42/EF Directive on machine safety
73/23/EEC Low voltage directive
89/336/EEC EMC directive
and are produced in accordance with the following standards:
EN 292-1 Machine safety
EN 292-2 Machine safety
EN 60 204-1 Electrical equipment for machinery, part 1 – General
requirements
We do not allow use of the units until the machine into which the parts are to be
incorporated has been declared to be in full accordance with the relevant directives.
Recycling The unit is designed to last for many years. When the time comes for the unit to be
recycled, the unit should be recycled according to national rules and procedures to
protect the environment.

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Service guide
Overview
Introduction This section contains any relevant information for the service of the BasX unit.
It includes:
•a survey for the planning of service inspections
•a description of all the components that require preventive maintenance
•general information on spare parts, fault finding etc.
Below please find a list of the main sections.
Preventive
maintenance
For optimum operation conditions and a long life it is necessary to perform preventive
maintenance on the various unit parts within the stipulated intervals. Read more about
intervals in section “Scheduling service inspections, overview”, page 7
Guarantee The factory guarantee is only valid when the preventive maintenance is in accordance
with the guidelines of this section. Written documentation must be available.
Quick and easy Dantherm Air Handling A/S has put great efforts into making the maintenance work as
quick and easy as possible.
Among other things the unit has inspection doors for easy access to the parts to be
serviced.
Warning! Do not forget to disconnect all current to the unit and the unit parts before service.
Contents This section includes the following:
Item See page
Scheduling service inspections, overview next page
Preventive maintenance 9
Spare parts 24
Fault finding guide 25
Service agreement 26

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039073 • Version 1.0 • 05.03.2007
Scheduling service inspections, overview
Introduction This section gives an overview of the parts to be regularly serviced.
Read more in each section of each part about what kind of service is necessary and
how to carry out this service inspection.
Categories Dantherm Air Handling has categorized the service inspections to be carried out:
•Four times a year
•Every 5000 operating hours or at least once a year
•Once a year
•When the catalogue value for recommended end pressure loss is exceeded
Four times a year Check the following parts at least four times a year to ensure optimal operating
performance:
Component Service Reference
Rotary heat
exchanger
Check and tighten the belt-drive Page 15
Fan Check and tighten the pulley Page 11
Once a year Check the following parts at least once a year to ensure optimal operating performance:
Component Service Reference
Cabinet Clean the cabinet
Check the seals and closing mechanisms
Page 10
Damper Check the air-tightness Page 22
Rotary heat
exchanger
Check the condition of the rotor and that it turns
easily
Check the brush seals
Check the drive system
Page 15
Cross-flow heat
exchanger
Check the heat exchanger
Check the air-tightness of the bypass damper
Lubricate the movable parts of the bars
connected to the damper motor
Clean the drip tray, drain and water trap
Page 13
Run-around heat
exchanger
Check the condition of the coils
Vent the coils
Clean the drip tray, drain and water trap (exhaust
air)
Check the droplet eliminator (exhaust air)
Check the pump
Page 17
Heating coil Check the condition of the coil
Vent the water coil
Page 20
Continued overleaf

8
Scheduling service inspections, overview, continued
Once a year,
continued
Component Service Reference
Cooling coil Check the condition of the coil
Vent the coil which use water
Clean the drip tray, drain and water trap
Check the droplet eliminator
Page 21
Fan Check the fan impeller
Check the vibration isolators and flexible
connections
Page 11
Catalogue value The following parts should be checked at least when the catalogue value for
recommended end pressure loss is exceeded to ensure optimal operating performance:
Component Service Reference
Bag filter Replace the filter cells and check the seals at the
filter cells
page 19

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039073 • Version 1.0 • 05.03.2007
Preventive maintenance
Introduction In order to achieve the best possible operation and long lifetime of the air handling unit
it is necessary to perform preventive maintenance of the various parts of the air
handling unit within the necessary intervals. Read more about intervals in the section
“Scheduling service inspections, overview”, page 7
Condition for
warranty
The factory warranty is only valid if documented preventive maintenance has been
carried out by the instructions in this section. The documentation could be in form of a
written log.
Contents This section covers the following topics:
Topic See page
How to service the cabinet 10
How to service fans and fan motors 11
How to service the cross-flow heat exchanger 13
How to service the rotary heat exchanger 15
How to service run-around heat exchangers 17
How to service the filter 19
How to service the heating coil 20
How to service the cooling coil 21
How to service dampers 22

10
How to service the cabinet
Interval Clean the cabinet once a year.
Before you start
Before you start Make sure to have the following available before you start servicing the cabinet:
•Cloth, water, and if needed, detergent
Caution! Remember to switch off the main power supply to the unit and its parts before starting
the service inspection!
Illustration This illustrates the cabinet:
Procedure Follow the procedure below to service the cabinet:
Step Action
1 Dry it off with a dry cloth or use water mixed with a cleaning product
2 Clean the seals and inspection doors, and check for leakage.
Dantherm Air Handling recommends treating the seals with a moisture
repellent agent
3 Check the seals and closing mechanisms

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039073 • Version 1.0 • 05.03.2007
How to service fans and fan motors
Interval Fan and motor are serviced in accordance with the following intervals:
4 times annually:
•Belt drive
Once annually:
•Fan wheel
•Vibration dampers and flexible connections
Warning! Do not forget to disconnect all current to the unit and the unit parts before service.
Illustrations Belt-driven fans
Direct-driven fans
Plug fans
Procedure Do as follows to service the fan:
Step Action
1 Check and clean, if necessary, the fan wheels for dust that may cause
unbalance and vibrations. If necessary, replace the bearings
2 Steps 2-4 only apply to belt-driven fans!
Check the belt drive for wear and tear and replace the belts if necessary.
NB: If one belt of a belt drive is worn, all belts of the belt drive are to be re-
placed! Do not use new and used belts together, as they are of different lengths
Continued overleaf

12
How to service fans and fan motors, continued
Procedure, continued Step Action
3 Check that the pulleys are placed correctly and are completely parallel
4 Check that the fixing of the belt drive has been correctly adjusted.
Check the belt tightening by controlling that the deflection (F) matches the
specifications below (mm). The deflection strength of each belt depends on
the belt profile type used and the centre distance.
Dantherm Air Handling recommend the use of special-purpose tools for the
measuring of the belt tightening in order to ensure the control of the values
of the table below
Belt Profile
(type)
Centre
Distance (mm)
Deflection
Strength (Kg)
Deflection,
F (mm)
500-600 11SPA-XPA
600-800
2,7
13
Procedure, 5000
operation
hours/annually’)
Do as follows to service the fan ball bearings:
Step Action
1 Check the wear and tear of the vibration-damping rubber bushings*) into
which the fans’ ball bearings are fitted
*) only fans that have rubber bushings
2 Control the vibration dampers and the flexible connections

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039073 • Version 1.0 • 05.03.2007
How to service the cross-flow heat exchanger
Interval The cross-flow heat exchanger is serviced once annually.
Before start The following should be available before start:
•A soft brush
•Fat-dissolving detergent
•High-pressure cleaner with atomizer
Warning! Do not forget to disconnect all current to the unit and its parts before service.
Take care when cleaning the exchanger so that you do not damage the surface of the
heat exchanger.
Avoid the use of hard objects on the surface.
Special
conditions
Where a unit is used in connection with exhaust e.g. from a kitchen with fatty air,
exhaust hood filters etc. must be cleaned every day to ensure optimum performance
and to protect the heat exchanger. The unit must be switched off, when the fat filters
are removed.
Illustration A cross-flow heat exchanger:
Preventive
maintenance
To ensure a long lifetime and continuous operation of the DanX unit, the cross-flow
heat exchanger should be maintained once annually as described below. See
”Procedure”.
Note! Take care when cleaning the rotary heat exchanger so that you do not damage the
surface of the heat exchanger.
Continued overleaf

14
How to service the cross-flow heat exchanger, continued
Procedure,
preventive
maintenance
The preventive maintenance is done as described below:
Step Action
1 Check the heat exchanger plates and inlet for dirt.
(You may use a torch to see through it from both sides)
2 Dust should be removed from the inlet edges. Use a soft brush
3 Internal fat and dirt is dissolved and removed by detergent
4 Subsequently you may use a high-pressure cleaner with atomizer to rinse
the heat exchanger internally – use compressed air for dry dirt.
Water and dirt is removed from the opposite side of the exchanger
Procedure,
service
The cross-flow heat exchanger is serviced as described below:
Step Action
1 Check that the edges of the heat exchanger plates are clean and intact
2 Use a soft brush to remove dust on the edges of the heat exchanger
3 Wash with fat-dissolving detergent to remove fat or dirt on the edges of the
heat exchanger
4 If necessary, clean the heat exchanger by means of a high-pressure cleaner
with atomizer.
Use a water vacuum cleaner to remove water and dirt from the opposite side
of the heat exchanger
5 Clean the condensate tray under the heat exchanger as well as the drain
and the drain trap connected to it

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039073 • Version 1.0 • 05.03.2007
How to service the rotary heat exchanger
Illustration Rotary heat exchanger:
Interval To ensure a long lifetime and continuous operation of the BasX unit, the rotary
exchanger should be maintained once annually as described below. See ”Procedure”.
The rotary heat exchanger should be serviced once annually.
Before start The following should be available before service:
•Soft brush
•Fat-dissolving detergent
•Compressed air
•A vacuum-cleaner
Not included This section does not deal with service of the bypass damper, which is described
separately under Accessories. See “How to service dampers”, page 22
Warning! Do not forget to disconnect all current to the unit and its parts before service.
Take care when cleaning the rotary heat exchanger so that you do not damage the
surface of the heat exchanger.
Avoid the use of hard objects on the surface.
The preventive maintenance is done as described below:
Procedure,
preventive
maintenance
Step Action
1 Check the rotary exchanger for dirt.
(You may use a torch to see through it from both sides)
2 Dust should be removed from the inlet edges. Use compressed air, a
vacuum cleaner or a soft brush
3 Check that the brushes round the rotor are tight
Continued overleaf

16
How to service the rotary heat exchanger, continued
Procedure,
preventive
maintenance
The rotary heat exchanger is serviced as described below:
Step Action
1 Check that the brushes are intact
2 Use a soft brush to remove dust on the edges of the rotary heat exchanger
3 Wash with fat-dissolving detergent to remove fat or dirt on the edges of the
heat exchanger
4 If necessary, clean the heat exchanger by compressed air.
Use a vacuum cleaner to remove dirt from the opposite side of the heat
exchanger
5 Check that the brushes around the rotor are undamaged and tight-fitting.
6 Check the rotor driving belt and the transmission.

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How to service run-around heat exchangers
Intervals Once annually.
Before start The following must be available before service:
•Compressed air or vacuum cleaner
•a soft brush
Warning! Do not forget to disconnect all current to the unit and the unit parts before service.
Take care not to damage the slats of the coils.
Illustration The run-around heat exchanger:
Reduction of
capacity
After many hours of operation dust may settle on the coil surfaces. This can reduce the
recovery capacity, and preventive maintenance is consequently important.
Procedure Do as follows to service the run-around heat exchanger:
Step Action
1 Check the coils for dust or dirt. If necessary, clean the alu slats by a soft
brush and a vacuum cleaner.
Alternatively you may blow compressed air through the coil against the
normal air direction
2 Straighten any bent slats using appropriate tools
3 Air the coil circuits through the exhaust valve of the pipe system (air in the
pipe system may reduce the capacity)
4 Service the pump according to the pump manufacturer’s directions
5 Check the positive pressure of the pressure expansion system. If necessary,
pump it to the correct level
Continued overleaf

18
How to service run-around heat exchangers, continued
Procedure,
continued
Step Action
6 Clean the condensate tray, the drain and the drain trap from the drip tray
under the cooling coil
7 Check and clean the eliminator plate (if the unit is equipped with one). Use
compressed air and a soft brush

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039073 • Version 1.0 • 05.03.2007
How to service the filter
Interval Replace the filter when the pressure loss exceeds recommended end pressure, see the
table.
The intervals are dependent on the concentration of dust in the air passing through the filter.
Use the following ways to determine if the filter needs to be replaced:
•Use a filter monitor (if fitted) giving a signal with a lamp or another electrical device
when the filter is to be replaced
•Use a pressure difference manometer which shows the filter pressure drop, see the
table
If no mechanical equipment is available to check the pressure loss, the filter should be
replaced when estimated necessary.
Before you start No special tools are required for the service inspection.
Caution! Remember to switch off the main power supply to the unit and its parts before starting
the service inspection!
Illustration This illustrates the bag filter:
Procedure Follow the procedure below to replace the bag filter:
Step Action
1 Release the bag filters by turning the handles
2 Pull out the filters of the unit
3 Clean the frame profiles
4 Check that the rubber strips are intact and undamaged
5 Carefully push the new bag filters into the unit to ensure that they are sealed
properly
Recommended
end pressure
This table shows the recommended end
pressure referred to in this section:
Type Value
G3 150
F5 250
F6 250
F7 250
F8/9 350

20
How to service the heating coil
Intervals Once annually.
Before start The following must be available:
•Compressed air or a vacuum cleaner
•A soft brush
Warning! Do not forget to disconnect all current to the unit and the unit parts before service.
Take care not to damage the slats of the coils.
Do not touch the hot coils.
Illustration The heating coil:
Procedure Do as follows to service the heating coils:
Step Action
1 Check the coils for dust or dirt. If necessary, clean the alu slats by a soft
brush or a vacuum cleaner.
Alternatively you may blow compressed air through the coil against the
normal air direction
2 Straighten any bent slats using appropriate tools
3 Check that the clip-on sensors are properly fixed
4 Air the coil circuits through the exhaust valves of the pipe system (air in the
pipe system may reduce the capacity)